Effect of Tool Wear on Machining GFRP and AISI D2 Steel Using Alumina Based Ceramic Cutting Tools

The alumina based ceramic cutting tools are used to machine glass fibre reinforced plastic (GFRP) composite material and AISI D2 steel. The machining studies were conducted using Ti[C,N] mixed alumina based ceramic cutting tool (CC650) and SiC whisker reinforced alumina based ceramic cutting tool (CC670). Machining process was performed at different cutting speeds at constant feed rate and depth of cut and the flank wear of the cutting tools were measured. From the machining studies, the wear behaviour of the cutting tool are studied and compared with reference to the work material. Very smooth wear land was observed while machining GFRP composite whereas, ridges and groves were observed while machining steel using alumina based ceramic cutting tools. The hard metal chips produced during machining has induced to undergo the severe in changes on machining D2 steel. Based on the flank wear, tool face fibre / matrix chip has prone to maximum wear of 0.4mm compared to machining a metal. On machining AISI D2 steel the machining has reduced one fold (1:2) than the GFRP composite material. In summary, Ti[C,N] mixed alumina cutting tool performance better on machining AISI D2 steel and SiC whisker reinforced alumina cutting tool for machining GFRP composite.